PROCESS FOR AN COMMISSIONING ACTIVITIES :Prepared by

COTMAC

Chethan Kumar.G

STEP TO BE TAKEN IN COMMISSIOINING TIME PERIOD :Planning/Preparation for an Site Visit. Safety Materials. Discussion with the Project Team. Plan to Pay Your Kind Attention Towards Your Project. Initial Supervision of Dcs System After Reaching Site & Plan for Dcs System Power-On. Supervision in field for Erection Activities. Loop Test. Drive Checking. Closed Loop & Open Loop Checking. Pid Tuning. Take Backup in a Regular Intervals. Try to Maintain Official Relationship with Customer. Maintain Your Documents. Conduct SAT with Customer & Handover the system to customer.

1. PLANNING/PREPARATION FOR AN SITE VISIT :Whenever engineer Plans to move from an site Visit. He have to carry certain Necessary Materials with him. Which is Related Document to that Projects. Doc. Are Like :-

Project I/O List. BOM Copy Stands for Bill Of Material. HDM Copy Stands for Hardware Design Manual. SDM Copy Stands for Software Design Manual. FAT Doc. Copy Stands for Factory Acceptance Test Report. KOM Copy Stands for Kick Off Meeting Copy. FAT MOM Copy Stands for FAT Minutes of Meeting Copy. System Architecture Copy. System Integration Datasheet Copy. Power-On Checklist. SAT Document Copy. CLCS Loop Protocol Stands for Closed Loop Protocol.

1. PLANNING/PREPARATION FOR AN SITE VISIT :DRIVE Protocol Copy. Instrument Protocol Copy. Commissioning Status Loop wise Protocol Copy. Weekly Progress Report Copy. Timesheet Copy. HSE Report Copy. The above mentioned doc are necessary to bring at site for a commissioning Activities. This doc. Can tell the real state what exactly happened during Fat Time Period. This will be proof for us. So, In case customer are trying to demand something from us. We can show this doc. So, this is necessity for all Engineer to bring doc. With them to Site.

2. SAFETY MATERIALS :It is must and clear to all the engineer who is working in automation Field must have to carry certain Safety materials with him to protect Themselves from accidents. Those Materials are :-

Safety Helmet Safety Shoes Safety Goggle Safety Glues Ear-Plugs

This are all the small Safety Materials which can save Your Life From Unpredictable Accident. So, Always work with Safety and go with Green. Maintain Honeywell Hse Report Properly. Try to get work from Our subcontractor with Safety. Conduct meeting in a regular interval with subcontractor and check there safety status.

3. Discussion with Project Team :Before Planning to visit for commissioning. Let u discuss with your particular Project Team. (Lead Engineer, Engineer Manager, Project Manager Exceptional case u can discuss have few discussion with Operational Manager in Honeywell also). Get backup from the lead-engineer, Cross-check those Backup which you received from the lead. Try to get there Number/Mail Id in case if any queries or clarification requires You can call and get Solution from them. Cross-check the backup which You have received from the Lead. Discuss with team regarding your role in commissioning. Also discuss about loop hole of Honeywell Dcs system which Honeywell was hided in front of customer. Discuss with team regarding your role in commissioning. Get the Customer details Ex Reporting Person (Name, Phone No, Mail Id) Get the Sub-contractor details Supervisor (Name, Phone No, Mail Id)

4. Plan to Pay Your Kind Attention Towards Your Project. :First of all get details about customer from Honeywell they might have experienced with customer during the time period of pre-fat and fat. Get the details about Reporting Time and Relieving Time from Site. Make Yourself Prepared on the same Manner. Plan to present Yourself in a well dressed Manner. Whenever you will plan to visit for a site. Plan according to keep entire project related doc with You. Plan to pay Official Hours at site premises. And also try to avoid taking unwanted leaves.

5. Initial Supervision of Dcs System After Reaching Site :At the Initial supervision of Dcs system. Check the room temperature. Whether room temperature is well maintained. Alternatively check for dustfree in control Room. And check for falls sealing and flooring system readiness. If this three points are well-Maintained/Prepared then we can start Proceeding remaining Process. Locate / Allign the System, Panels, Printers, Third-Party Devices as Per Complexity diagram. Check the panel internal Design . Whether system has been prepared as per the HDM copy. Check the grounding system. Whether entire grounding has done properly in Panel (SG, FG) Check entire System & Marshalling Cabinets Dressing in all Panels, if its not well dressed then supervise the dressing. And make it done Before Planning for a system Power-on

Check entire Devices Ferruling/Tagging are given Properly if Not then supervise the Tagging Activities. And make it done Before Planning for a system Power-on Cross verify the Ups incomer Voltage and current as per our Power-on Checklist. Also Check the PDB Incomer Voltage and current. EX - Vpn, Vne, Vpe. Connect the Fte, Fta, Internal Power-loop Connections (Tubes, Fans, FTA cards Supply, BPS, Pmio Power Supply, Controller Supply (DBK), Wet Contact Relay Supplies as per System Integration, Hdm copy and crossverify its tagging and ferruling . Cross-verify the grounding system. Check whether signal & Frame Ground are given properly as per HDM copy In Panel. Connect signal & frame grounding cable to panel bus-bar (individual bus bar already allocated for each panel). Also Cross-verify every signal grounds are loop internally, check the continuity for signal ground. As same like signal grounds frame ground has to have to same continuity with each other. Note :- Frame & Signal should not have continuity with each other. This is Very Important checkpoint has to be taken care before planning for a power-on

Check the preparation of earth pit whether customer/sub-contractor has made/prepared as per Honeywell standard. If its made then start to megger resistance with that pit. As per Honeywell standards SG- <1 ohm FG <5 ohm. If once we will get the same reading from the created pit. The same can be connected with our Dcs Panels grounding Bus-bars. Check the system whether entire system are connected with network. And also check the services are started and mingled with server. Run the Ntp setup and match entire network time with server time. Run the file replication and update graphics in entire network. Power-on the system as per Honeywell Checklist. And keep on updating checklist. Once System will be powered-on. Then get signature from customer in the checklist. After the system has been powered-on. Declare the same Information to the team in a official Manner by the way of giving mail to the entire team. And also attach the checklist.

6. Initial Supervision of Dcs System After Reaching Site :Plan to supervise field with Sub-contractor supervisor at initial stage and get planned from him about allocation of Man Power, Completion Date, Etc., Cross- check Honeywell Materials which is received by Customer (Cross check with BOM). Plan to supervise status of the field activities with Sub-contractor supervisor at initial stage. Plant to do the in parallel. Try to allocate manpower in parallel areas. Work has to show progress in all areas. Guide technically to all Electrician. Try to Supervise there work. If any problems it can be solved on the instant.

7. Loop Test :Normally in Dcs there are two types of loop checking system are there. They are :Cold-Loop Checking Hot-Loop Checking

Cold-Loop Check :During the Cold-Loop Checking the signals will be checked from TB Terminals Block to the system. It can be checked by the way of looping cable in TB and observing bit changeover in Dcs system. Hot-Loop Check :During the Hot-Loop Checking the signals will be checked from field (JBJunction Box, Mcc- Electrical Feeder) to dcs. Through the way of checking connectivity/ By the way of checking cores in a cable.

Before starting to take trail of all drives, closed Loop, system. The Loops signals should clear from field to avoid time loss during trail time period. It is mandatory to check the Loop signals from field to Dcs after System Power-on. The signals which have to be loop tested from Field (JB- Junction Box, Mcc- Electrical Feeders to Dcs. They are :Digital Input signals. Digital Output Signals. ( Pfc, Wet contact 230v ). Thermocouple Signals Rtd Signals Analog Input Signals. (2 Wire system (24v) , 4- Wire system (Pfc) ). Once the signals will be loop tested from field to Dcs then the Dcs system will be ready to take trail.

8. Drive / Motors / Pumps Checking :For drive checking initially the logics shall be checked with customer. Before Proceeding for taking trail certain things also needed to check from our end like Contacts of relay. Whether feeder requires (Pfc, 230v Wet Contact Relay ). As per the demand we can provide relay contact. Same inform You can get from Electrical Mcc Diagrams. Once logics & Relay Contact will be checked then we can proceed for taking trial a feeder (Meant to say Motor/drive) through Dcs. Hardly drives have two types :AC Drives DC Drives Drives are mainly used for controlling the speed of a motor. Like rolling of a kiln roller. we can control the roller by varying its speed (Analog Output from dcs (4-20 MA)

For Motors & Pumps Checking :For Motor and Pump, it will be same as like drive initially you can cross-verify logics with customer. Once logic will be finalized. Then you can go-ahead to take trial from Mcc feeder. For Motor and Pumps different application available as per process. Like :1. Conveyor 2. Fans 3. Motors

Normally in automation Sector certain Motors/Pumps are used based on application. Based on Application the Specification for particular machine will vary. Initially whenever you are planning to take trial from Mcc Feeder Requested the concern Electrical Engineer to Switch off the Power Circuit. Once Power Circuit if Off. We can take trail From Dcs through control circuit. Supply will not reach till to field. But, feeder will be running. By this way we can take trial of a feeder.
There are two classification of motor are available in Power Sector :LT Motor Low Torque Motor. HT Motor - High Torque Motor. This classification between motors applies for application. Based on Application the Motors are classified. LT Motor :LT Motor stands for Low Torque Motor. To start this motor it requires less initial torque. (Ex :- Conveyors) HT Motor :HT Motor stands form High Torque Motor. It requires High Initial Torque to start. (Ex :- ID Fan)

9. Closed Loop & Open Loop Checking :Closed Loop :Example for an closed Loop Is PID Loop. Pid stand for Proportional + Integral + Derivative Loop Control Pid can be loop tested through Dcs by applying (4-20 ma) from Dcs. By the way of varying o-100 Command. And parley we have to cross check with its position feedback which is an analog input will tells the Control valve opening/closing status. So as per the command we need to get the position feedback from field. Once this Loop tune finishes we can make Pid in auto mode. And we can vary set point as per process. Pv-sp = op based on this philosophy the controller will control the Pid loop. In power sector certain Process applies Closed Loops Like :1. Drum level Control. 2. Combustion Control. 3. Atemperator Control. ( Temperature, Pressure ) 4. Hot well Level Control. 5. Deaerator Level Control. This are all certain Parameters in a Power Plant which will be controlled by Pid Loop.

Open Loop :Example for an Open Loop Is Damper Control. Open loop can be tested through Dcs by applying (4-20 ma) from Dcs. By the way of varying o-100 % Command. And parley we have to cross check with its position feedback which is an analog input, tells the Control valve opening/closing status. So as per the command we need to get the position feedback from field.
In power sector certain Process applies Open Loops. They are : 1. ID Fan Damper Control. 2. FD Fan Damper Control.

These are all certain Parameters in a Power Plant which will be controlled by Open Loop.

10. PID Tuning :PID Tuning :Example for an closed Loop Is PID Loop. Pid stand for Proportional + Integral + Derivative Loop Control

Please refer. The attached above Picture which is clearly mentioned how the Pid works. Pid is basically an closed loop circuit. Set point (SP) :- Set point is an parameters (Temperature, Flow, Pressure, Level). Operator use to feed this set point to maintain the process parameter. Process Value (PV) :- Process Value / Control Value Is an parameter reading which comes from field (Transmitter) it can be either (Temperature, Flow, Pressure, Level). Output (OP) :- Pid Controller Output In the form of 0-100 % / 4-20 ma. Which operates the Control Value By using I2P Convertor / Positiner
OP = PV-SP ERROR

10. PID Tuning :PID Tuning :For Pid Tuning mainly 3 terms are used. They are :1. Proportional . 2. Integral. 3. Derivative.

Proportional :- (Gain Factor) :- Proportional is a gain factor for a Pid control which control the control valve stock length speed. Default it will be 1. If stock will be fast then this gain factor can be reduce. By reducing this gain factor the control stock length can be controlled.
Integral :- (Offset Time) :- Integral is an Offset Time for a Pid control which control the offset time between process value with set point. By Increasing/decreasing this offset time Pid sp = Pv Equalization can be done soon. Derivative :- (Unstable Condition) :- Derivative is an Unstable Condition for a Pid control which makes the normal Pid in unstable condition. Before Tuning a Pid Control set the op Limit (Lower, Higher Limit). Which can save the plant from the unwanted trip.

11. Take Backup in a Regular Intervals. :Try to backup in a regular Intervals. If some unexpected things we can be in a safe zone. It is a good way to take backup daily and even it will secure for us. In Honeywell system certain system backup can be taken on site on daily basis. They are :Erdb Emdb Host Files Exported Files Checkpoint Qdb Graphics

Log Report Exported Assets Alarm Groups R400 Menu & Toolbars. Station File.

How to take backup in Honeywell System

12. Try to Maintain Official Relationship with Customer. :Try to Maintain Official Relationship with Customer :Represent Yourself in a good Manner. Try to avoid speaking regional language with Customer. If You will speak in a regional they may demand to do some Extra Work Not in an official manner in a Personal way. So, Always try to make Conversation in English with Customer. Try to follow the company Timing on Site. Dont do any extra activities which is not known by your Team. Dont commit anything by verbal Communication. Whatever, Commitment You will give to Customer do it in Official Manager By the way of giving a detailed mail to entire Team Members. Dont take any big discussion by your oneself. Let you give a mail to company. Let them take a discussion and give you confirmation. Then you can proceed for that.

13. Maintain Your Documents :Maintain Your Documents :Always give much priority for documentation works. Only documentation can tell how much activities u have done on site. In Honeywell We have certain Doc. Which need to be taken signed from customer after completion of particular activities. Those doc. are :Weekly Progress Report Time-sheet Power-on Checklist Drive Protocol Instrument Protocol Closed Loop Protocol HSE Report Commissioning status Protocol Mom Copies SAT Procedure Copies. Site Change Report (Honeywell SCR Report)

14. Conduct SAT with Customer & Handover the system to customer :Conduct SAT with Customer & Handover the System to Customer :After Finishing the entire Commissioning activities. Request Customer to give permission for Conducting SAT Procedure at Site. Before conducting sat in front of Customer. Let u check our system first whether entire redundancy system is ok (Pre-sat) If You will get Satisfaction then declare a day for conduct sat at site. Conduct sat in front of Customer and show them the redundancy of Dcs system and other check-up which is cleared mentioned in sat procedure. After completion of this procedure, sit with customer and make a final mom and get signed from customer in sat and mom copies.

THANK YOU

Thank you all to spend your precious time for my presentation